LED light engine for signage

Abstract

A durable LED light engine includes an printed circuit board including LEDs mounted thereon positioned between a substantially U-shaped top enclosure and a bottom enclosure. Once assembled together using alignment holes and projections, the open spaces in the combination of the substantially U-shaped top enclosure, the printed circuit board and the bottom enclosure are filled with a plastic sealant. Once cooled, the plastic sealant holds the combination of the substantially U-shaped top enclosure, the printed circuit board and bottom enclosure together.

What is claimed is: 
     
       1. An LED light engine comprising:
 a printed circuit board including:
 a top surface on which is mounted at least one LED; 
 a bottom surface on which is mounted electronic componentry and insulated wires; 
 at least one alignment hole between said top surface and said bottom surface; 
 an edge surrounding said printed circuit board between said top and bottom surfaces; 
 
 a substantially U-shaped top enclosure including:
 a top surface having at least one lens formed therein; 
 downwardly depending sides for surrounding said edge of said printed circuit board; 
 a bottom surface having at least one alignment piece constructed and arranged to pass through said at least one alignment hole in said printed circuit board; 
 
 a bottom enclosure including:
 a top surface including at least one alignment receptacle formed therein and a pair of channels extending the length of said top surface; 
 said pair of channels constructed and arranged to position said insulated wires; 
 
 a sealant material enabling:
 forming a strain relief around said insulated wires at either end of said substantially U-shaped top enclosure; 
 filling said pair of channels and said insulated wires positioned therein; 
 affixing said downwardly dependent sides of said substantially U-shaped top enclosure, said edge of said printed circuit board and said bottom enclosure one to another; and 
 
 wherein the top of said printed circuit board is in direct physical contact with a portion of the bottom surface of said substantially U-shaped too enclosure and the bottom of said printed circuit board is in direct physical contact with a portion of the top surface of said bottom enclosure. 
 
     
     
       2. The LED light engine as defined in  claim 1  further including a projection having a mounting hole formed therein, said projection extending from the end of said bottom enclosure. 
     
     
       3. The LED light engine as defined in  claim 1  wherein said sealant material is not in contact with the top surface of said printed circuit board. 
     
     
       4. The LED light engine as defined in  claim 2  wherein the projection having a hole formed therein and extending from the end of the bottom enclosure is formed by said sealant material. 
     
     
       5. A method for making an LED light engine comprising;
 constructing a printed circuit board including:
 a top surface on which is mounted at least one LED; 
 a bottom surface on which is mounted electronic componentry and insulated wire; 
 at least one alignment hole between said top surface and said bottom surface; 
 an edge between said top surface and said bottom surface; 
 
 constructing a substantially U-shaped top enclosure including:
 a top surface having a number of lenses equal to the number of LEDs on said top surface of said printed circuit board; 
 downwardly depending sides for surrounding said edge of said printed circuit board; 
 a bottom surface having alignment pieces constructed and arranged to pass through said at least one alignment hole in said printed circuit board; 
 
 constructing a bottom enclosure including:
 a top surface including at least one alignment receptacle formed therein and a pair of channels extending the length of said top surface, said pair of channels formed to position said insulated wires; 
 
 placing said printed circuit board between said downwardly dependent sides of said substantially U-shaped top enclosure and aligning it therewith by placing said at least one alignment hole over said at least one alignment piece; 
 placing said top of said bottom enclosure over the bottom of said printed circuit board and aligning it therewith by alignment of said at least one alignment receptacle with said alignment pieces on the bottom of said substantially U-shaped top enclosure; 
 placing said combination of said substantially U-shaped top enclosure, said printed circuit board and said bottom enclosure in a plastic mold; 
 injecting plastic sealant material into said combination of said substantially U-shaped top enclosure, said printed circuit board and said bottom enclosure enabling:
 forming a strain relief around said insulated wires at either end of said substantially U-shaped top enclosure; 
 filling said pair channels and covering said insulated wires positioned therein; 
 affixing said downwardly dependent side of said substantially U-shaped top enclosure, said edge of said printed circuit board and said bottom enclosure one to another; and 
 
 wherein the to of said printed circuit board is in direct physical contact with a portion of the bottom surface of said substantially U-shaped top enclosure and the bottom of said printed circuit board is in direct physical contact with a portion of the to surface of said bottom enclosure.